Display module

ABSTRACT

A portable computing device is disclosed. The portable computing device can take many forms such as a laptop computer, a tablet computer, and so on. The portable computing device can include a single piece housing and a display module. The display module can include a protective top glass cover that is bonded to a plastic display frame and surrounded by a seal frame. The display module can also include a display panel and its associated circuitry suspended from the display frame below the protective glass cover. The display module is coupled to the single piece housing using mounting clips in a manner that allows the display module to move relative to the single piece housing during an impact event. The plastic display frame can include inserts that provide structural support near openings in the single piece housing.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of patent application Ser. No.14/630,434, filed Feb. 24, 2015, which is a continuation of patentapplication Ser. No. 13/541,614, filed Jul. 3, 2012, now U.S. Pat. No.8,971,028, which is a continuation of patent application Ser. No.12/694,168, filed Jan. 26, 2010, now U.S. Pat. No. 8,238,087, whichclaims the benefit of provisional patent application No. 61/292,739,filed Jan. 6, 2010, all of which are hereby incorporated by referenceherein in their entireties. This application claims the benefit of andclaims priority to patent application Ser. No. 14/630,434, filed Feb.24, 2015, patent application Ser. No. 13/541,614, filed Jul. 3, 2012,now U.S. Pat. No. 8,971,028, issued Mar. 3, 2015, patent applicationSer. No. 12/694,168, filed Jan. 26, 2010, now U.S. Pat. No. 8,238,087,issued Aug. 7, 2012, and provisional patent application No. 61/292,739,filed Jan. 6, 2010.

This patent application is related to and incorporates by reference intheir entirety the following patent applications:

(i) U.S. patent application Ser. No. 12/694,085 entitled “HAND HELDCOMPUTING DEVICE” by Ternus et al. filed Jan. 26, 2010;

(ii) U.S. patent application Ser. No. 12/694,200 entitled “COMPONENTASSEMBLY” by McClure et al. filed Jan. 26, 2010;

(iii) U.S. patent application Ser. No. 12/694,162 entitled “ASSEMBLY OFDISPLAY MODULE” by McClure et al. filed Jan. 26, 2010; and

(iii) U.S. patent application Ser. No. 12/694,166 entitled “PRINTEDCIRCUIT BOARD” by McClure et al. filed Jan. 26, 2010; and

(iv) U.S. patent application Ser. No. 12/694,083; and entitled “EDGEBREAK DETAILS AND PROCESSING” by Sweet et. al. filed Jan. 26, 2010 thatis, in turn, a continuation in part of and claims priority to U.S.patent application Ser. No. 12/580,934 entitled “METHOD AND APPARATUSFOR POLISHING A CURVED EDGE” by Lancaster et al filed Oct. 16, 2009 thattakes priority under 35 U.S.C. 119(e) to U.S. Provisional PatentApplication Ser. No. 61/249,200 entitled “COMPLEX GEOGRAPHICAL EDGEPOLISHING” by Johannessen filed Oct. 6, 2009.

BACKGROUND

Field of the Described Embodiments

The described embodiments relate generally to portable computing devicessuch as laptop computers, tablet computers, and the like. Moreparticularly, enclosures of portable computing devices and methods ofassembling portable computing devices are described.

Description of the Related Art

In recent years, portable computing devices such as laptops, PDAs, mediaplayers, cellular phones, etc., have become small, light and powerful.One factor contributing to this reduction in size can be attributed tothe manufacturer's ability to fabricate various components of thesedevices in smaller and smaller sizes while in most cases increasing thepower and or operating speed of such components. The trend of smaller,lighter and powerful presents a continuing design challenge in thedesign of some components of the portable computing devices.

One design challenge associated with the portable computing device isthe design of the enclosures used to house the various internalcomponents. This design challenge generally arises from a numberconflicting design goals that includes the desirability of making theenclosure lighter and thinner, the desirability of making the enclosurestronger and making the enclosure more esthetically pleasing. Thelighter enclosures, which typically use thinner plastic structures andfewer fasteners, tend to be more flexible and therefore they have agreater propensity to buckle and bow when used while the stronger andmore rigid enclosures, which typically use thicker plastic structuresand more fasteners, tend to be thicker and carry more weight.Unfortunately, however, the increased weight consistent with the morerugged enclosure can lead to user dissatisfaction whereas bowing ofenclosures formed of lightweight material can result in damaging some ofthe internal components (such as printed circuit boards) of the portabledevice.

Furthermore, the enclosures are mechanical assemblies having multipleparts that are screwed, bolted, riveted, or otherwise fastened togetherat discrete points. These assembly techniques typically complicate thehousing design and create aesthetic difficulties because of undesirablecracks, seams, gaps or breaks at the mating surfaces and fastenerslocated along the surfaces of the housing. For example, a mating linesurrounding the entire enclosure is produced when using an upper andlower casing. Moreover, the various components and complicated processesused to manufacture the portable device can make assembly a timeconsuming and cumbersome process requiring, for example, a highlytrained assembly operator working with special tools.

Another challenge is related to techniques for mounting structureswithin the portable computing devices. Conventionally, the structureshave been laid over one of the casings (upper or lower) and attached toone of the casings with fasteners such as screws, bolts, rivets, etc.That is, the structures are positioned in a sandwich like manner inlayers over the casing and thereafter fastened to the casing. Thismethodology suffers from the same drawbacks as mentioned above, i.e.,assembly is a time consuming and cumbersome process.

In view of the foregoing, there is a need for improved component densityand associated assembly techniques that reduce cost and improve outgoingquality. In addition, there is a need for improvements in the manner inwhich handheld devices are assembled such as improvements that enablestructures to be quickly and easily installed within the enclosure. Itis also desirable to minimize the Z stack height of the assembledcomponents in order to reduce the overall thickness of the portablecomputing device and thereby improve the overall aesthetic look and feelof the product.

SUMMARY OF THE DESCRIBED EMBODIMENTS

A portable computing device is disclosed. The portable computing devicecan include at least a single piece housing having a front opening, thesingle piece housing further comprising an integral bottom and sidewalls that cooperate to form a cavity in cooperation with the frontopening, an edge of the side walls surrounding and defining the frontopening, a display module disposed within the front opening and securedto the seamless housing without a bezel. In the described embodiment,the display module can include at least a display frame, a display panelsupported by the display frame, a protective cover supported by thedisplay frame used to protect the display panel, and a plurality ofattachment features incorporated into the display frame, wherein theplurality of attachment features secure the display module to thehousing when the portable computing device is deemed to be adequatelyfunctional.

In particular embodiments, the display module can include a protectiveglass cover bonded to display frame and surrounded by a seal that iscoupled to the display frame. The display module can include a touchscreen mounted below the protective glass cover. Further, a displaypanel housing including a display panel and its associated circuitry canbe mounted to the display frame such that the display panel is visiblethrough the protective glass cover.

In other embodiments, a method is described. The method can be carriedout by performing at least the following operations. Electricallyconnecting a display module configured for use in a portable computingdevice to at least one operational component located within a cavityformed by a housing of the portable computing device, temporarilysecuring the display module to a front opening that provides access tothe cavity, the temporarily secured display module effectively enclosingthe at least one operational component within the housing, functionallytesting the portable computing device; and if the portable computingdevice passes the functional testing, then securing the display moduleto the housing, otherwise, removing the display panel.

A method of assembling a display module to a portable computing devicewithout using a bezel is disclosed. In the described embodiment, theportable computing device has a single piece housing, the single piecehousing having a front opening, an integral bottom and side walls thatcooperate to form a cavity in cooperation with the front opening, and anedge of the side walls surrounding and defining the front opening. Themethod can be carried out by performing at least the following: placingthe display module within the front opening and secured to the seamlesshousing, and deploying an attachment feature, the attachment featurebeing incorporated into the display module.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, wherein likereference numerals designate like structural elements, and in which:

FIG. 1A shows a top view of a portable computing device in accordancewith the described embodiments.

FIG. 1B shows a perspective top view of a portable computing device inaccordance with the described embodiments.

FIG. 2 shows a perspective top view of a display frame and inserts priorto assembly in accordance with the described embodiments.

FIG. 3 shows a perspective top view of the display frame assembled withinserts and a seal frame prior to assembly in accordance with thedescribed embodiments.

FIG. 4 shows a perspective top view of the display frame assembled witha seal frame in accordance with the described embodiments.

FIG. 5 shows a perspective top view of the display frame assembled witha seal, a protective top glass and mounting clips in accordance with thedescribed embodiments.

FIG. 6 shows a perspective bottom view of mounting a display panelhousing to the protective top glass and frame assembly in accordancewith the described embodiments.

FIG. 7A shows a cross sectional view of a portable computing device withthe display frame and display panel in an assembled position inaccordance with the described embodiments.

FIG. 7B shows a cross sectional view of a portable computing device witha display module in a pre-assembled position in accordance with thedescribed embodiments.

FIG. 8 shows side views of a mounting mechanism in accordance with thedescribed embodiments.

FIG. 9 shows a side view of a fixture assembly in accordance with thedescribed embodiments.

FIG. 10 is a flow chart of a method for assembling a display frameincluding securing a protective glass layer to the display frame.

FIG. 11 is a flow chart of a method for integrating a display moduleinto a portable computing device.

DESCRIBED EMBODIMENTS

In the following paper, numerous specific details are set forth toprovide a thorough understanding of the concepts underlying thedescribed embodiments. It will be apparent, however, to one skilled inthe art that the described embodiments may be practiced without some orall of these specific details. In other instances, well known processsteps have not been described in detail in order to avoid unnecessarilyobscuring the underlying concepts.

This paper discusses an aesthetically pleasing portable computing devicethat is easy to carry with one hand and operate with the other. Theportable computing device can be formed of a single piece seamlesshousing and an aesthetically pleasing protective top layer that can beformed of any of a number of durable and strong yet transparentmaterials such as highly polished glass or plastic. For the remainder ofthis discussion, however, the protective top layer can take the form ofhighly polished cover glass without any loss in generality. Furthermore,the uniformity of the appearance of the portable computing device can beenhanced since (unlike conventional portable computing devices) thecover glass can be mounted to the single piece seamless housing withoutthe use of a bezel. This simplicity of design can accrue many advantagesto the portable computing device besides those related to aesthetic lookand feel. For example, fewer components and less time and effort can berequired for assembly of the portable computing device, and the absenceof seams in the single piece housing can provide good protection againstenvironmental contamination of internal components. Moreover, theability of the portable computing device to successfully withstandapplied loads (such as from day to day use) as well as those from lessfrequent but potentially more damaging events such as being dropped canbe substantially improved over conventional portable computing devices.

In the described embodiments, the single piece seamless housing can beformed from plastic or metal. In the case where the single pieceseamless housing is formed of metal, the metal can take the form of asingle sheet (such as aluminum). The single sheet of metal can be formedinto a shape appropriate for housing various internal components as wellas providing various openings into which switches, connectors, displays,and so on can be accommodated. The single piece seamless housing can beforged, molded, or otherwise processed into a desired shape. The shapeof the housing can be asymmetric in that an upper portion of the housingcan be formed to have a substantially different shape than thatexhibited by a lower portion of the housing. For example, the upperportion of the housing can have surfaces that meet at distinct anglesforming well defined boundary whereas the lower portion can be formed tohave a surface with a spline shape. The transition zone between theupper portion having distinct edges and the lower, spline shaped portioncan take the form of an edge having a rounded shape providing both anatural change from the upper portion of the housing (i.e., the area ofdistinct edges) and the smoother surface presented by the lower portionof the housing. It should also be noted that in addition to providing amore aesthetically pleasing transition, the rounded shape of the edge inthe transition zone can provide a more comfortable feel when being heldin a user's hand either during use or merely being carried about. One ofthe advantages to using metal for the housing is ability of metal toprovide good electrical grounding for any internal components requiringa good ground plane. For example, performance of a built in RF antennacan be substantially improved when a good ground plane is provided.Moreover, a good ground plane can be used to help mitigate thedeleterious effects caused by, for example, of electromagneticinterference (EMI) and/or electrostatic discharge (ESD).

It should be noted that throughout the following discussion, the term“CNC” is used. The abbreviation CNC stands for computer numericalcontrol and refers specifically to a computer controller that readscomputer instructions and drives a machine tool (a powered mechanicaldevice typically used to fabricate components by the selective removalof material). It should be noted however, that any appropriate machiningoperation can be used to implement the described embodiments and is notstrictly limited to those practices associated with CNC.

These and other embodiments are discussed below with reference to FIGS.1-10. However, those skilled in the art will readily appreciate that thedetailed description given herein with respect to these figures is forexplanatory purposes only and should not be construed as limiting. Inparticular, with respect to FIGS. 1A and 1B, a portable computing deviceis described. In FIGS. 2-6, various stages of assembling displaycomponents associated with the portable computing device are described.In FIGS. 7A-7B, securing assembled display components to a portablecomputing device housing are discussed. In FIG. 8, an alternate couplingmechanism for securing the assembled display components to the portablecomputing device housing are discussed. In FIGS. 9 and 10, a fixtureassembly and a method of using the fixture assembly to secure aprotective top glass to a display frame and seal assembly are described.In FIG. 11, a method of assembling a portable computing device isdescribed.

FIG. 1A illustrates a specific embodiment of portable computing device100. More specifically, FIG. 1A shows a full top view of fully assembledportable computing device 100. Portable computing device 100 can processdata and more particularly media data such as audio, video, images, etc.By way of example, portable computing device 100 can generallycorrespond to a device that can perform as a music player, game player,video player, personal digital assistant (PDA), tablet computer and/orthe like. With regards to being handheld, portable computing device 100can be held in one hand by a user while being operated by the user'sother hand (i.e., no reference surface such as a desktop is needed). Forexample, the user can hold portable computing device 100 in one hand andoperate portable computing device 100 with the other hand by, forexample, operating a volume switch, a hold switch, or by providinginputs to a touch sensitive surface such as a display or pad.

Portable computing device 100 can include single piece seamless housing102 that can be formed of any number of materials such as plastic ormetal which can be forged, molded, or otherwise processed into a desiredshape. In those cases where portable computing device 100 has a metalhousing and incorporates RF based functionality, it may be advantageousto provide at least a portion of housing 102 in the form of radio (orRF) transparent materials such as ceramic, or plastic. In any case,housing 102 can be configured to at least partially enclose any suitablenumber of internal components associated with the portable computingdevice 100. For example, housing 102 can enclose and support internallyvarious structural and electrical components (including integratedcircuit chips and other circuitry) to provide computing operations forportable computing device. The integrated circuits can take the form ofchips, chip sets, modules any of which can be surface mounted to aprinted circuit board, or PCB, or other support structure. For example,a main logic board (MLB) can have integrated circuits mounted thereonthat can include at least a microprocessor, semi-conductor (such asFLASH) memory, various support circuits and so on.

Housing 102 can include opening 104 for placing internal components andmay be sized to accommodate a display assembly or system suitable forproviding a user with at least visual content as for example via adisplay. In some cases, the display system can include touch sensitivecapabilities providing the user with the ability to provide tactileinputs to portable computing device 100 using touch inputs. The displaysystem can be formed of a number of layers including a topmost layerbeing a transparent protective layer 106 formed of polycarbonate orother appropriate plastic or highly polished glass. Using highlypolished glass, protective layer 106 can take the form of cover glass106 substantially filling opening 104. Seal 108 can be used to form agasket between cover glass 106 and housing 102. Seal 108 can be formedof a resilient material such as a plastic along the lines ofthermoplastic urethane or TPU. In this way, seal 108 can provideprotection against environmental contaminants from entering the interiorof portable computing device 100. Racetrack 110 can be defined as theuppermost portion of the housing 102 that surrounds cover glass layer106. In order to maintain the desired aesthetic look and feel ofportable computing device 100, it is desirable that any offsets betweenthe housing 102 and cover glass 106 be minimized by centering racetrack110.

Although not shown, the display panel underlying cover glass 106 can beused to display images using any suitable display technology, such asLCD, LED, OLED, electronic or e-inks, and so on. Display assembly may beplaced and secured within the cavity using a variety of mechanisms. Inone embodiment, the display system is snapped into the cavity. It may beplaced flush with the adjacent portion of the housing. In this way, thedisplay can present visual content that can include video, still images,as well as icons such as graphical user interface (GUI) that can provideinformation the user (e.g., text, objects, graphics) as well as receiveuser provided inputs. In some cases, displayed icons can be moved by auser to a more convenient location on the display. For example, GUI canbe moved by the user manually dragging GUI from one location to a moreconvenient location. The display can also provide a user with tactilefeedback provided by a number of haptic actuators usually, but notalways, arranged in an array of haptic actuators incorporated into thedisplay. In this way, the haptic actuators can provide the user withtactile feedback.

In some embodiments, a display mask (not shown) can be applied to, orincorporated within, or under cover glass 106. The display mask can beused to accent an unmasked portion of the display used to present visualcontent. The display mask can be used to make less obvious home button112 used to provide a specific input such as change display mode, forexample to portable computing device 100. The display mask can renderhome button 112 less obvious by, for example, being closer in tone orcolor to home button 112. For example, if home button 112 is formed of amaterial that is somewhat darker (such as gray or black) than coverglass 106, then using a similarly colored display mask can reduce thevisual impact of home button 112 when compared with the unmasked portionof cover glass 106. In this way, the visual impact of home button 112can be reduced by being integrated into the overall look of the displaymask. Furthermore, the display mask can provide a natural mechanism fordirecting the attention of a viewer to the unmasked area of the displayused to present visual content.

Portable computing device 100 can include a number of mechanicalcontrols for controlling or otherwise modifying certain functions ofportable computing device 100. For example, power switch 114 can be usedto manually power on or power off portable computing device 100. Mutebutton 116 can be used to mute any audio output provided by portablecomputing device 100 whereas volume switch 118 can be used toincrease/decrease volume of the audio output by portable computingdevice 100. It should be noted that each of the above described inputmechanisms are typically disposed through an opening in housing 102 suchthat they can couple to internal components. In some embodiments,portable computing device 100 can include a camera module configured toprovide still or video images. The placement may be widely varied andmay include one or more locations including for example front and backof the device, i.e., one through the back housing, the other through thedisplay window.

Portable computing device 100 can include a mechanism for wirelesscommunications, as either a transceiver type device or receiver only,such as a radio, portable computing device 100 can include an antennathat can be disposed internal to a radio transparent portion of housing102. In some embodiments, an antenna can be incorporated into seal 108or cover glass 106. In other embodiments, a portion of housing 102 canbe replaced with radio transparent material in the form of an antennawindow described in more detail below. The radio transparent materialcan include, for example, plastic, ceramic, and so on. The wirelesscommunications can be based on many different wireless protocolsincluding for example 3G, 2G, Bluetooth, RF, 802.11, FM, AM, and so on.Any number of antennas may be used, which can use a single window ormultiple windows depending on the needs of the system. In oneembodiment, the system can include at least first and second antennawindows built into the housing (upper and logo).

FIG. 1B shows a perspective top view of portable computing device 100 inaccordance with the described embodiments. As shown in FIG. 1B, portablecomputing device 100 can include one or more speakers 120 used to outputaudible sound. Portable computing device 100 can also include one ormore connectors for transferring data and/or power to and from portablecomputing device 100. For example, portable computing device 100 caninclude multiple data ports, one for each configuration of portrait modeand landscape mode. However, the currently described embodiment includessingle data port 122 that can be formed of connector assembly 124accommodated within an opening formed along a first side of housing 102.In this way, portable computing device 100 can use data port 122 tocommunicate with external devices when portable computing device 100 ismounted in docking station. It should be noted that in some cases,portable computing device 100 can include an orientation sensor or anaccelerometer that can sense the orientation or movement of portablecomputing device 100. The sensor can then provide an appropriate signalwhich will then cause portable computing device 100 to present visualcontent in an appropriate orientation.

Connector assembly 124 can be any size deemed appropriate such as, forexample, a 30 pin connector. In some cases, the connector assembly 124can serve as both a data and power port thus obviating the need for aseparate power connector. Connector assembly 124 can be widely varied.In one embodiment, connector assembly 124 can take the form of aperipheral bus connector, such as a USB or FIREWIRE connector. Thesetypes of connectors include both power and data functionality, therebyallowing both power delivery and data communications to occur betweenthe portable computing device 100 and the host device when the portablecomputing device 100 is connected to the host device. In some cases, thehost device can provide power to the media portable computing device 100that can be used to operate the portable computing device 100 and/orcharge a battery included therein concurrently with the operating.

FIG. 2 shows a perspective top view of a display frame 200 and inserts,202, 204, 206, 208 and 210 prior to assembly. The display frame 200 canbe formed from a material, such as a plastic or a metal. For instance,the display frame can be formed using thermoplastic urethane or TPU. Theinserts can be used to provide additional structural support andreinforcement in regions where the display frame is proximate toopenings in the housing 102 (see FIGS. 1A and 1B). For example, insert202 is proximate to an opening for a mechanism switching power on oroff, insert 204 is proximate to an opening for a mechanism that enablesa muting function to be activated and a mechanism that enables volumecontrol, insert 206 is proximate to an opening for multi-pin connectorand insert 210 is proximate to an opening for an audio output interface,a microphone and a boot switch.

In particular embodiments, insert 208 can be eliminated. When insert 208is included, it can provide structural support for an opening. Theopening can be associated with a number of different functions. Forinstance, the opening can be used to provide audio output from aninternal speaker, to insert or remove a Sim card, to provide externalaccess to an external power and/or data pin connector, to providesupport for a docking interface and to provide access to additionalactuator, such as a switch or a button.

In general, the number, placement location and size of the inserts canbe varied and is not limited to the example of FIG. 2. For example, inone embodiment, as described above, the opening and its associatedinsert 208 can be eliminated. In other embodiments, the opening for themuting and volume control mechanisms can be moved away from the cornerresulting in changes to the display frame 200 and a change in a locationof insert 204 to accommodate the different location of the opening. Inanother example, a size of insert 206 can be increased to accommodatemultiple connectors, such as a separate power and data connectors.

The inserts can be formed into an appropriate shape from a rigidmaterial, such as a metal (e.g., stainless steel or magnesium). In oneembodiment, the inserts can be formed from a polymer, such as IXEF™manufactured by Solvay Advanced Polymers, LLC. As is shown in FIG. 3,the inserts can be incorporated into the display frame 200. In oneembodiment, the inserts can be mechanically snapped into place. Inanother embodiment, an adhesive, such as an epoxy can be used to attachthe inserts to the display frame.

In yet another embodiment, the inserts can be loaded into a plasticmolding tool to form an integrated assembly, such as a plastic/metalassembly when metal inserts are used with a plastic display frame 200.After forming the display frame 200 and inserts, the inserts canincorporated into the display frame 200 and the combined assembly can beloaded into an over mold tool. The over mold tool can be used to applyan additional layer of plastic that bonds the inserts to the displayframe 200. When the inserts are integrated into the display frame inthis manner, a number of apertures can be designed into the inserts toimprove adhesion between the insert material and the display framematerial when additional plastic is added.

FIG. 3 shows a perspective top view of the display frame 200 assembledwith inserts and a seal frame 108 prior to assembly in accordance withthe described embodiments. FIG. 4 shows a perspective top view of thedisplay frame 200 assembled with a seal frame 108 in accordance with thedescribed embodiments. In one embodiment, the seal 108, when coupled tothe display frame 200 (see FIG. 4), can rest on a ledge 205 b around anouter perimeter of the display frame. The seal 108 can include a ledge205 a, around its perimeter, that rests on ledge 205 b when the twocomponents are seated against one another.

In particular embodiments, the seal can include gaps, such as 201, thatallow a component, such as a mounting tab (see FIGS. 5 and 6), securedto the display frame 200, to extend from the display frame 200. The seal108 can also include gaps associated with openings in the housing 102(e.g., see description of inserts with respect to FIGS. 2 and 3). Theseal 108 can have parts, such as 203, that include posts and ledges thathang below a top surface of the seal. The posts can be aligned withindentations in the display 200 to form a conformal fit and prevent theseal from sliding relative to the display frame 200. When the seal 108is coupled to the display frame 200 (see FIG. 4), the parts, such as203, can extend underneath the display frame 200 (see FIG. 7 for across-sectional view). For example, portions of seal 108 can be locatedbeneath ledge 205 b on the display frame 200. In particular embodiments,the seal 108 can be coupled to the display frame using an adhesive, suchas an epoxy, using a fastener, such as a screw, or combinations thereof.

In FIG. 4, the seal 108, display frame 200 and inserts are shownassembled. A protective top glass layer can be placed on top of theassembly. FIG. 5 shows a perspective top view of the display frame 200assembled with a seal 108, a protective top glass 106 and mounting clips212 in accordance with the described embodiments. The top glass 106 ismounted to the display frame 200, inserts and seal 108 as shown in FIG.4. A method of mounting the top glass 106 to the display frame 200 isdescribed with respect to FIGS. 9 and 10. The top glass 106 includes andaperture 214 for button 112 (see FIGS. 1A and 1B).

Mounting clips 212 are attached to the display frame 200. In oneembodiment, the mounting clips 212 are coupled to the display frame 200using a fastener, such as a screw. The mounting clips 212 can be used tosecure the display components shown in FIG. 5 within housing 102.Details of the display components relative to the housing 102 andmounting clips 212 are described with respect to FIG. 7A.

FIG. 6 shows a perspective bottom view of mounting a display panelhousing 220 to the protective top glass and frame assembly in accordancewith the described embodiments. As is shown in FIG. 7, the display panelhousing 220 can support and secure a display panel 224 and associateddisplay circuitry 226. A touch screen 222 can be mounted below theprotective top glass 106. As previously described, the mounting clips212 can be secured to the display frame 200 via a fastener, such as 216.

As described in more detail with respect to FIG. 7A, when assembled, thedisplay panel housing 220 hangs below display frame 200. The displaypanel housing 220 includes a number of mounting tabs with an aperture,such as 219. Fasteners 218 can be threaded through the apertures in themounting tab and secured to corresponding mounting ports in the displayframe 200. In one embodiment, the display panel 224 within the housing220 can be attached to a bottom portion of touch screen 222 using anappropriate fixing agent, such as an epoxy or an adhesive tape. Thedisplay panel 224 can also be sealed to the back of the protective layerusing a gasket, such as 223, that can be adhered to the display using anadhesive material.

In an impact invent, such as dropping the portable computing device,impact stresses can be distributed through out the portable computingdevice. During the impact invent, the stress loads experienced by eachcomponent can depend on the direction of the impact and how eachcomponent is coupled to one another. For example, the mounting tabs 219couple to the display panel housing 220, display panel 224 andassociated circuitry to the display frame 200. Depending on a number ofmounting tabs that are used, the coupling between the display panelhousing and display frame can be tighter or looser. Typically, thetighter the coupling between the two components, the more the twocomponents tend to move as a single unit. Tighter coupling can beaccomplished by using more mounting tabs, such as 219, between thedisplay panel housing 220 and looser coupling can be accomplished byusing relatively less mounting tabs.

In impact events, it was found that providing the display panel 224 witha greater capability for flexure reduced the likelihood of a stresscrack forming in the display panel 224. In one embodiment, the displaypanel housing 220 is only coupled to the display frame 200 at the endsto provide more flexure. The display panel housing 220 is proximatelyrectangular and the mounting tabs are located on the shorter sidesproviding the greatest distance between mounting tabs on the two sidesin which they are placed. Thus, during an impact invent, flexing canoccur over a greater length and the stresses can be more spread out.

Also, it was found that placing the mounting tabs 219 in lower stressareas tended to reduce the likelihood of a stress crack forming in thepanel during an impact event. A stress distribution for the displaypanel housing 220 and its associated components can be predicted fordifferent impact invents to determine optimum locations to place themounting tabs. In another embodiment, the mounting tabs, such as 219,can be located in areas that are predicted to have lower stresses thanother areas, such that less stress is transferred to the display panelhousing 220 from the display frame 200. Further, a total number ofmounting tabs can be reduced to decrease the coupling between thedisplay frame 200 and the display panel housing 220. For instance, nomounting tabs are found on two of the sides of the display panel housing220 and a number mounting tabs on the other sides can be reduced, suchas the three mounting tabs 219 shown on each side in FIG. 6.

FIG. 7A shows a cross sectional view of a portable computing device witha display module 225 including the display frame 200 and display panel224 in an assembled position within the housing 102. The display module225 is assembled from the components shown in FIG. 6. The display panelhousing 220 includes a frame or one or more brackets that secure thedisplay panel 224 and the display circuitry 226. The seal 108 on thedisplay frame is in contact with a lip 228 of the housing 102. In anassembled position, when the device 100 is facing upwards, i.e., theprotective top glass 106 is facing upwards, the display panel housing220 and its associated display components are suspended or hang downfrom the display frame 200.

To install the display module 225 into the housing 102. The mountingclips 212 which are distributed around the perimeter of the displayframe 200 (e.g., see FIGS. 5 and 6) are compressed towards the displayframe 200 allowing the mounting tabs 212 to move past the lip 228 of thehousing. Once a tip of the mounting clip 212 clears the lip 228, themounting tab can expand outward underneath the lip 228 and into a notch227 in the display housing 102. In the expanded position, the mountingclips, such as 212, can prevent the display frame 200 and its associatedcomponents from being removed from the housing 102. More details ofinstalling the display module 225 into the housing are described withrespect to FIG. 7B.

In particular embodiment, the notch can be formed by removing arectangular portion of housing 102. The width of the notch can be widerthan the width of clip 212 to accommodate the clip 212. A number of thenotches can be formed around the perimeter of housing 102 to accommodateeach of the clips 212. The number of clips can be varied and hence thenumber of notches formed in the housing can be varied between designs.

Compressive forces, such as 229, can be used to keep the protective topglass, flush with the top of housing. These forces can be applied to thedisplay frame 200 or other components coupled to the display frame 200,such as the display panel housing 220. The forces, such as 229, can beapplied at a number of locations throughout the device 100 and are notlimited to the location indicated by 229. As an example, in somelocations, the display frame 200 or its associated components can be incontact with foam or another material, such as a high-strength foam,that is in compression. The material can be placed in compression whenthe display frame 200 is inserted into the housing 102.

The compressed material can apply a compressive force upwards to thedisplay frame 200. The compressive force can cause the mounting clips,such as 212, to move or spread outwards, i.e., towards the housing 102.In another embodiment, one or more springs (not shown) can be used toprovide a compressive force directly to the display frame 200 or theforces can be provided through one or more intermediary componentslinked to the display frame 200. For instance, a spring can be locatedunder a component that is under the display frame 200. The spring can beoriented to press upwards against the component and towards the displayframe 200. The component can be in contact with display frame 200 totransfer a compressive force from the spring to the display frame 200via the component.

During a drop event, the seal 108 and/or the mounting clips, such as212, can allow some lateral movement and provide some force dampening.For instance, when a force is applied in the direction 231, the seal 108and possibly one or more of the mounting clips, such as 212 can becompressed absorbing a portion of the force. One or more of the mountingclips on a side opposite (not shown) can expand or stretch outward,i.e., lengthen. The expansion of the mounting clips outward on theopposite side can keep the display assembly in place. After the seal 108and/or mounting clip 212 uncompress, the display frame can move in theopposite direction of force 231. This type of interaction involving acompression and subsequent expansion of the seal 108 and movements ofthe mounting clip can occur for any resultant forces that are parallelto top surface of the protective glass 106, such as a resultant force inthe opposite direction of 231 or a resultant force perpendicular to 231(i.e., into the page).

FIG. 7B shows a cross sectional view of a portable computing device 100with a display module 225 in a pre-assembled position in accordance withthe described embodiments. During installation of the display module 225to the housing 102 shims, such as 241, can be inserted between thehousing 102 and the mounting clips. The shims, such as 241, hold themounting clip in a compressed position 212 a. In one embodiment, anumber of shims can be used, such as one shim for each clip. In otherembodiments, a single shim can be used for multiple mounting clips. Forexample, a single shim can be used to compress all of the mounting clipson a side of the display module 225. In yet another embodiment, a shimtool that follows the inner perimeter of housing 102 near the lip 228can be used to compress all of the shims at one time. The shim tool canbe removed as a single piece to allow the mounting clips to engage.

The display module 225 can be connected to the electrical componentswithin the portable device and the display module 225 can be testedprior to removing the shims, such as 241, that allow the mounting clips,such as 212 a to engage. Besides the display module 225, otherelectrical internal electrical components such as a main logic board canbe also tested since one the display module 225 is installed directaccess to many of the internal components is no longer possible. Once itis determined that display module and/or electrical components areoperating acceptably, the shims can be removed. A testing method isdescribed in further detail with respect to FIG. 11.

After the shims are removed and mounting clips expand into place, thedisplay module 225 and other internal components can be re-tested. If itis determined that there is a malfunction, it may be necessary to removethe display module 225 from the housing 102. An upward force can beapplied pull the display module 225 away from the housing. In oneembodiment, the upward force can be applied using a device, such as asuction cup 243.

In a particular embodiment, the upward force on the display module canbe applied until one or more of the mounting clips break. For example,the upward force can be applied on one corner of the display module andthen the mounting clips can be broken in a zipper like fashion, i.e.,one at a time. When enough of the mounting clips are broken (it may notbe necessary to break all of the mounting clips to remove the displaymodule 225), the display module 225 can removed from the housing. Afterthe display module 225 is removed, broken clip portions can be removedfrom the interior of the housing 102 and needed repairs can bedetermined. If the display module 225 is functioning properly, newmounting clips can be installed in the display module 225 and thedisplay module 225 can be reinstalled. In some embodiments, it may bepossible to remove the display module 225 without breaking the mountingclips. One such example is described as follows with respect to FIG. 8.

FIG. 8 shows side views of a mounting mechanism 232 in accordance withthe described embodiments. The mounting mechanism 232 includes threetrack portions, such as 231 in contact with and configured to move alonga track 234. Two bump portions, such as 210, are located between thethree track portions. The mounting mechanism can be a sheet, such as ametal sheet with some width and some thickness. The sheet can be bent orshaped to form 232 or some shape proximate to the 232. The mountingmechanism is shown in an unloaded configuration, 230 a and a loadedconfiguration, 230 b.

The mounting mechanism can be configured such that when a force, such as236, is applied and the mounting mechanism is loaded, the bump portionsflatten and the mounting mechanism lengthens. The lengthening of themounting mechanism causes the end track portions to move outwards andslide along track 234. After the mounting mechanism 232 is unloaded, itcan be designed to return to its unloaded configuration, 230 a, wherethe height of the bumps increases and the end track portions move inwardto allow the mounting mechanism to shorten.

In one embodiment, the mounting mechanism 232 can be used as alternateto the mounting clips, such as 212, or can be used in conjunction withthe mounting clips, such as 212 (see FIGS. 7A and 7B). The mountingmechanism 232 can be located on a side of the display frame 225 likemounting clip, 212. Referring to FIG. 7B, in an unloaded position, priorto installing the display module 225, the mounting mechanism 232 canstick out past the housing lip 228. A load can be applied to themounting mechanism 232 to flatten it and allow the display module 225 toslide past the lip 228.

After the lip 228 is cleared, the load can be removed from the mountingmechanism. The mounting mechanism 232 can then expand to lock thedisplay module 225 into place. For instance, the mounting mechanism 232could sit in notch 227 when expanded. The notch 227, in this example,can also be a slot to accommodate both bumps of the mounting mechanism232 rather than forming separate notches for each bump.

The display module 225 can be removed after it has been installed inhousing 102. Using mounting mechanisms, such as 232, the display module225 can be removed by inserting a thin strip, such as a thin metalblade, between the seal 108 and the lip 228. The thin strip can beinserted between the bumps of the mounting mechanism 232. The thin stripcan be slid over to one side or the other to load and flatten one of thebumps of the mounting mechanism, which flattens the other bump. When themounting mechanism is flattened, it may be possible to lift the displaymodule 225 such that the mounting mechanism slides by the lip 228 of thehousing allowing the display frame to be removed without breaking themounting mechanism 232.

As previously described with respect to FIG. 7B, using clips 212, thedisplay module 200 can be removed by lifting the display frame andbreaking mounting clips, such as 212. For instance, suction cups can beapplied to the top of protective glass 106 to lift out the displaymodule 225. To re-install the display module 225, new mounting clips canbe attached. One advantage of mounting mechanism 232 is that it may bepossible to remove the display module 225 without breaking mountingmechanism 232.

FIG. 9 shows a side view of a fixture assembly 244. With respect to FIG.9, a method of assembly is described that can be used to provide an evenspacing around the perimeter of the protective top glass 106 between theprotective top glass 106 and seal 108. The fixture 244 can be used tosecure the display frame 200 such that a surface that supports theprotective top glass 106 is in a horizontal position. In one embodiment,the protective top glass can be seated on a portion of the seal 108 anda portion of the frame 200 as is shown.

An adhesive, such as 238, can be applied to the display frame 200. Forinstance, a line of liquid epoxy can be applied around the display frame200 as an adhesive. Next, a shim ring 240 can be placed in contact withan inner surface perimeter of the seal 108 (The shim ring is configuredto conform to the inner perimeter of the seal 108, which is proximatelyrectangular.) Then, the protective top glass layer can be placed betweenthe shim ring and in contact with the adhesive 238.

A weight, such as 242 can be placed on top of the protective glass layer106. In one embodiment, the weight can be held in place by the shim ring240. The weight 242 can be used to keep the protective top glass 106horizontal while the adhesive is curing. Finally, in one embodiment, thefixture 244 and its content can be placed in an oven to aid in curing ofthe adhesive 238. In one embodiment, a curing time can be about ½ hour.

FIG. 10 is a flow chart of a method 300 for assembling a display frame,such as 200, including securing a protective glass layer, such 106, tothe display frame. In 302, a display frame including a seal as describedwith respect to FIG. 4 can be provided. Providing the display frame caninvolve forming a plastic display frame and inserts for structuralreinforcement, loading the inserts into the display frame, adding aplastic layer over the inserts to bond the inserts to the display frameand bonding the seal 108 to the display frame including the inserts, aswas previously described. In 304, a display frame and seal can be loadedinto a fixture assembly as described with respect to FIG. 9. In 306, anadhesive can be applied to the display frame secured in the fixtureassembly.

In 308, a shim ring can be placed proximate to an inner edge of the sealon the display frame 200. In 310, the protective glass can be placedwithin the shim ring and in contact with the adhesive. In 312, a weightcan be placed over the protective glass. In 314, the fixture assemblywith the display frame can be placed in a curing device, such as anoven. In 316, the fixture assembly and the associated components can beplaced in the curing device for some time period to allow the bondbetween the protective top glass and the adhesive to form. Then, thefixture assembly can be removed from the oven, the weight and the shimring can be removed and the display frame with the bonded protective topglass can be removed from the fixture assembly.

FIG. 11 is a flow chart of a method 400 for integrating a display moduleinto a portable computing device. In 402, the display module can beelectrically connected to at least one operational component of theportable computing device. In 404, the display module can be temporarilysecured to the portable device housing (see FIG. 7B). In 406, theportable computing device can be functionally tested. In 410, adetermination can be made in regards to whether the device has passed atesting regimen. When the device passes the testing regimen, in 412, thedisplay module can be secured to the housing (see FIG. 7A).

When the device does not pass the test regimen, in 414, the displaymodule can be disconnected and removed from the housing. Since themounting clips have not been engaged yet, the display module can beremoved without breaking the mounting clips. In 416, necessary repairsfor the portable device can be determined and components can be replacedas needed. Then, the method can be repeated starting with 402.

The various aspects, embodiments, implementations or features of thedescribed embodiments can be used separately or in any combination.Various aspects of the described embodiments can be implemented bysoftware, hardware or a combination of hardware and software. Thedescribed embodiments can also be embodied as computer readable code ona computer readable medium for controlling manufacturing operations oras computer readable code on a computer readable medium for controllinga manufacturing line. The computer readable medium is any data storagedevice that can store data which can thereafter be read by a computersystem. Examples of the computer readable medium include read-onlymemory, random-access memory, CD-ROMs, DVDs, magnetic tape, optical datastorage devices, and carrier waves. The computer readable medium canalso be distributed over network-coupled computer systems so that thecomputer readable code is stored and executed in a distributed fashion.

The foregoing description, for purposes of explanation, used specificnomenclature to provide a thorough understanding of the invention.However, it will be apparent to one skilled in the art that the specificdetails are not required in order to practice the invention. Thus, theforegoing descriptions of specific embodiments of the present inventionare presented for purposes of illustration and description. They are notintended to be exhaustive or to limit the invention to the precise formsdisclosed. It will be apparent to one of ordinary skill in the art thatmany modifications and variations are possible in view of the aboveteachings.

The embodiments were chosen and described in order to best explain theprinciples of the invention and its practical applications, to therebyenable others skilled in the art to best utilize the invention andvarious embodiments with various modifications as are suited to theparticular use contemplated. It is intended that the scope of theinvention be defined by the following claims and their equivalents.

While the embodiments have been described in terms of several particularembodiments, there are alterations, permutations, and equivalents, whichfall within the scope of these general concepts. It should also be notedthat there are many alternative ways of implementing the methods andapparatuses of the present embodiments. For example, although anextrusion process is preferred method of manufacturing the integraltube, it should be noted that this is not a limitation and that othermanufacturing methods can be used (e.g., injection molding). It istherefore intended that the following appended claims be interpreted asincluding all such alterations, permutations, and equivalents as fallwithin the true spirit and scope of the described embodiments.

What is claimed is:
 1. An electronic device, comprising: a housing witha bottom wall and side walls, wherein the bottom wall and side wallsdefine a front opening of the electronic device; a display module in thefront opening that is secured to the housing, wherein the display modulecomprises a display frame, a display supported by the display frame, anda cover glass that overlaps the display; and a plurality of attachmentfeatures that secure the display module to the housing, wherein theplurality of attachment features comprises: a seal that separates thedisplay module from the side walls in a first direction, wherein thedisplay module does not overlap the sidewalls in a second direction thatis perpendicular to the first direction, a first portion of the sealoverlaps the display module in the second direction, and a secondportion of the seal does not overlap the display module in the seconddirection; and mounting clips that contact the side walls of the housingand the display frame, wherein the display frame is interposed betweenthe mounting clips and the cover glass.
 2. The electronic device definedin claim 1, wherein each mounting clip comprises a first portion that issubstantially parallel to a surface of the display module.
 3. Theelectronic device defined in claim 2, wherein the first portion of eachmounting clip is directly adjacent to the display module and whereineach mounting clip is secured to the display module by a respectivefastener.
 4. The electronic device defined in claim 3, wherein eachmounting clip comprises a second portion that protrudes into arespective recess in the housing.
 5. The electronic device defined inclaim 1, wherein the seal is formed from a resilient material.
 6. Theelectronic device defined in claim 1 wherein the display is a touchscreen supported by the display frame and wherein the mounting clips areconfigured to provide a compressive force that supports the displayframe.
 7. An electronic device, comprising: a housing with a top openingand side walls surrounding the top opening; a touch screen in the topopening; a display panel housing positioned in the top opening andoverlapped by the touch screen; a display panel in the display panelhousing, wherein the display panel is adhesively attached to a bottomsurface of the touch screen, wherein the display panel and the displaypanel housing are separated from the side walls by gaps; a frame thatsupports the display panel housing, wherein the display panel housing issuspended from the frame; and mounting clips attached to the frame thatmaintain the gaps between the display panel housing and the sidewalls.8. The electronic device defined in claim 7, further comprising a coverthat is positioned above the display panel.
 9. The electronic devicedefined in claim 7, wherein the electronic device is a tablet computer.10. An electronic device having an interior and an exterior, theelectronic device comprising: a housing having a bottom wall and sidewalls, wherein the bottom wall and side walls define a front opening ofthe electronic device and wherein the side walls have a cavity; adisplay module in the front opening and having first and second opposingsurfaces, wherein the first surface forms a portion of the exterior ofthe electronic device and the second surface faces the bottom wall ofthe housing and wherein the display module comprises a display frame anda cover glass mounted to the display frame; mounting clips that securethe display module to the housing, wherein the mounting clips have afirst portion attached to the display frame and a second portion thatextends from the display module into the cavity of the side walls andwherein the display frame is interposed between the mounting clips andthe cover glass.
 11. The electronic device defined in claim 10 whereinthe first portion of the mounting clips are attached to the displayframe with fasteners.
 12. The electronic device defined in claim 11wherein the display module further comprises a touch screen that ismounted between the cover glass and the bottom wall of the housing. 13.The electronic device defined in claim 12 wherein the display modulefurther comprises a display panel housing directly attached to the touchscreen.